Honeycomb Filter Cell Arrangement for Pressure Loss Reduction
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Solution Overview
Problem
Existing honeycomb filters face challenges in minimizing initial pressure loss and the increase in pressure loss after particulate matter (PM) accumulation, due to limited exhaust gas flow directions and uneven cell volumes adjacent to the outer wall, leading to inefficient filtration and increased resistance.
Innovation Solution
A honeycomb filter design where each exhaust gas emission cell is fully surrounded by introduction cells across porous cell walls, with a greater total volume of emission cells adjacent to the outer wall, allowing for uniform gas flow and maximizing filtration area, reducing initial pressure loss and its increase after PM accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If exhaust gas emission cells are fully surrounded by introduction cells across porous cell walls, then filtration area is maximized and pressure loss is reduced, but device complexity increases due to precise cell arrangement requirements
Solution Approach 1:
The honeycomb filter is divided into multiple cells with specific functions (introduction cells and emission cells) arranged in a coordinated pattern. Each cell is segmented to perform a specific role in the exhaust gas flow path, with introduction cells positioned to surround emission cells, creating an efficient filtration structure that reduces pressure loss while maintaining manageable complexity through modular design.
Solution Approach 2:
Different regions of the honeycomb filter have different cell configurations optimized for their specific functions. The cells adjacent to the outer wall have a greater total volume of emission cells compared to introduction cells, while internal cells have equal volumes. This local optimization ensures efficient exhaust gas flow and filtration throughout the entire filter structure, reducing overall pressure loss.
2Ease of operation
If cells adjacent to outer wall have greater total volume of emission cells, then exhaust gas flow distribution is improved and pressure loss is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies different volume ratios of emission cells to introduction cells in different regions of the honeycomb filter. Specifically, cells adjacent to the outer wall have a greater total volume of emission cells compared to introduction cells, while internal cells have equal volumes. This local differentiation optimizes exhaust gas flow distribution across the entire filter, ensuring efficient operation while maintaining manufacturability through clear design specifications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves low initial pressure loss and a gradual increase in pressure loss even after significant PM accumulation, enhancing fuel economy and reducing filtration resistance.
Implementation Method 1
porous cell walls defining the cells, the cells including exhaust gas introduction cells each having an open end at an exhaust gas inlet side and a plugged end at an exhaust gas outlet side and exhaust gas emission cells each having an open end at the exhaust gas outlet side and a plugged end at an exhaust gas inlet side
Implementation Method 2
porous cell walls defining the cells
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
A honeycomb filter including a plurality of honeycomb fired bodies being combined with one another via adhesive layers therebetween, wherein each honeycomb fired body includes an outer wall on its outer periphery thereof, a plurality of cells as exhaust gas passages, and porous cell walls defining the cells, the cells including exhaust gas introduction cells each having an open end at an exhaust gas inlet side and a plugged end at an exhaust gas outlet side and exhaust gas emission cells each having an open end at the exhaust gas outlet side and a plugged end at the exhaust gas inlet side. The exhaust gas introduction cells and the exhaust gas emission cells each have a uniform cross-sectional shape throughout from the end at the exhaust gas inlet side to the end at the exhaust gas outlet side excluding the plugged portion in a direction perpendicular to the longitudinal direction of the cells; each exhaust gas emission cell is adjacently surrounded fully by the exhaust gas introduction cells across the porous cell walls, except for the cells adjacent to the outer wall; and the cells adjacent to the outer wall consist of the exhaust gas introduction cells and the exhaust gas emission cells, the total volume of the exhaust gas emission cells adjacent to the outer wall being greater than that of the exhaust gas introduction cells adjacent to the outer wall.